Coating process for etched-look label

ABSTRACT

A film, and process for making the same, that can be used as a label and which provides an etched appearance by the application of the combination of at least two layers of coarse-grained inks. A more specific form of the invention is to prepare a heat-shrink over-wrap film label as disclosed and then apply it to a regular glass bottle so as to create the appearance of an all-over etched treatment or a look of etched treatment to specific areas only. According to another more specific version of the invention, a heat-shrinkable overwrap sleeve may be printed as described above with a portion of the finish gradated from a full strength coating on the main body section of the container to a lesser degree in a continuous gradation over to a narrower neck part of the bottle to be covered. When the heat-shrinkable film is applied on a container with a narrow neck, the degree of frost effect remains uniform, being counter-balanced by the lesser application of the frost effect in the area where a higher degree of shrinkage takes place.

TECHNICAL FIELD

This invention relates to a process for providing a simulated etched orfrosted look to a surface, as well as a product made from this process.More specifically, the invention relates to a coated label film that maybe applied to a bottle to simulate the look of an etched or frostedouter surface.

BACKGROUND OF THE INVENTION

A now-popular packaging style for wine and other beverages in glassbottles is to treat the exterior of the bottle with a physical orchemical etching process to create a soft matte or frosted appearance.The etch treatment can be all-over, in a design, or with area(s) omittedfor screen printing.

Physical etching is accomplished by sandblasting fine particles againstthe surface to be decorated. In chemical etching, an acid is applied toreact with the glass surface. Either method is laborious, costly,involves the use of harsh chemicals, and produces waste materialrequiring expensive disposal. Also, some assert that a glass bottle sotreated may suffer impaired strength.

The work of others who have addressed this challenge are described inU.S. Pat. Nos. 6,099,944; 5,571,557; and 6,214,424.

SUMMARY OF THE INVENTION

The present invention provides a film that can be used as a label andwhich is provided with an etched appearance by the application of thecombination of at least two layers of inks. These coatings cause lightto reflect at random on both layers and creates the effect of a deepfrost finish which simulates the effect on the glass currently achievedby the chemical or physical etching process.

A more specific form of the invention is to prepare a heat-shrinkover-wrap film label as described above and then apply to a regularglass bottle so as to create the appearance of an all-over etchedtreatment or a look of etched treatment to specific areas only.

According to another more specific version of the invention, a heatshrink overwrap sleeve may be printed as described above with a portionof the finish gradated from a full strength coating on the main bodysection of the container to a lesser degree in a continuous gradationover to a narrower neck part of the bottle to be covered. When the heatshrink film is applied on a container with a narrow neck, the degree offrost effect remains uniform, being counter-balanced by the lesserapplication of the frost effect in the area where a higher degree ofshrinkage takes place.

Other details, aspects and features of the invention with respect toboth process and product will be described below.

BEST MODE FOR CARRYING OUT THE INVENTION

It is well known to apply labels made of a flexible film substrate toglass and plastic bottles using either a pressure sensitive adhesive orby providing a sleeve over-wrap which is shrunk by application of heatin order to closely conform the film label to the outside shape of thecontainer. Such labeling substrates are usually printed with the desiredornamentation or indicia on an inward side of the label film that isapplied toward the container. In this manner, the printing will not bescuffed or marred during manufacture, shipping, handling, or prior toand after sale. Such labels are very durable and present an attractive,relatively glossy appearance.

The treatment of glass with a physical or chemical etching process tocreate a soft matte etched or frosted appearance is well known.Recently, glass bottles for wine and other beverages have been sotreated to provide an attractive look. However, when an adhesive labelis applied to such bottles, even when the label is produced fromtransparent film material, the etched or frosted appearance is lost inthe area covered by such a label.

The present invention provides a label and process for making the samewhich will simulate the etched or frosted appearance when applied to anordinary glass or plastic container, such as a jar or bottle. Examplesof this product and method are set forth below. It should be noted thatthese examples are representative only and do not represent all ways inwhich the invention can be practiced. These examples are illustrative ofthe Applicants' best currently-known mode for carrying out theinvention. As used herein, the terms “etched” and “frosted” are usedinterchangeably and to the extent a difference may be perceived in thetrade, it is a difference in degree only.

As an example, a commonly-used label substrate, such as PET or PVC film,may be treated according to the present invention. One side of the film,which is to become the inner side directed toward the glass surface, isprovided a coating of coarse-grained translucent ink. This coating isapplied in a way that intentionally creates an irregular surface on thefilm. This layer of ink is preferably provided without color pigment.The coarseness of the finished grain may be created by applying the inkwith a coarse grid gravure cylinder. An example of an appropriateapplication cylinder would be one which is chemically engraved orengraved using a system produced by Think Laboratory Company, Ltd. ofChiba, Japan, having a relatively coarse grid with a cell depth of about20-40 (20 preferred) microns and a line screen of about 125-200 linesper inch (150 preferred). A preferred ink for this coating may besolvent based Finelap 1285 Clear, manufactured by Sun ChemicalCorporation, with an additional about 2-3% by weight of 18-361 siliconpowder. One purpose of this inner side coating is to prevent what hasbeen called a “wet t-shirt” look caused by trapped moisture, which mayresult in distorted color, clarity/opacity, and gloss. In the case of alabel being adhesively applied to a surface this inner side coatingcould be omitted.

The opposite, outer side of the film also may be treated with one ormore coatings. Preferably, but optionally, a coating of translucentcolor solvent based nitrocellulose ink is applied directly to the outerside of the film. Thereafter, a coarse coating of matte ink having arelatively large particle size colorless pigment added thereto, whichprovides some opacity but not color, is applied to the outer side of thefilm. In preferred form, this ink may be solvent based Finelap 1285Matte, made by Sun Chemical Corporation, with the addition of about 5%by weight of 18-355 silicon powder. A high durability ink should beselected for this surface coat. Again, the coarseness of the finishedgrain of this matte ink is enhanced by application with a gravurecylinder chemically engraved to have a relatively coarse grid. Forexample, it may have a preferred cell depth of about 40 microns with aline screen of about 150 lines per inch.

As used herein, when referring to the application of a “coarse” or“coarse-grained” coating, it is intended to mean the use of relativelylarge particle size in the ink or lacquer being applied. In this case,pigment solids sized nearer the larger end of the spectrum of acceptablesize are selected. The coarseness of the ink and the manner in which itis applied contribute to its creating a coating of irregular thickness,even to the point of having a slightly textured feel in the case of theouter surface coating. It makes no difference whether the inner or outercoating of ink is applied to the film first, except that if a coating oftranslucent colored ink is applied to the outer side of the film, itmust be applied before the coarse layer of matte ink on the outersurface.

A purpose for providing a coating of pigmented ink on the outer surfaceof the film prior to application of the coarse-grained colorless mattecoating is to provide (1) the appearance that the underlying containeris made of a colored material (such as green or brown glass) and/or (2)to simulate the true color of the contained product. For example, if thecontainer is to appear to be that of etched clear glass containing red,white or blush wine, then a color of ink is selected for this layer soas to provide a similar color when used in combination with the coarsecoatings of colorless ink on one or both sides of the film label. It hasbeen found that the natural color of the inner product may be distortedor become unattractive when the label of the present invention is usedto simulate an etched or frosted look. Substantial compensation for orreversal of this undesired color change may be accomplished by selectingan appropriate color of translucent ink to be applied as describedabove. Alternatively, a color may be selected which simulates the colorof the product as seen through colored glass or to make the glass appearopaque. While this translucent color layer might be applied on the innerside of a transparent film substrate below the inner side coarse-grainedcoating, it has been found that applying it to the outer side of thefilm creates a more suitable effect.

A more particular form of the present invention is to use a heatshrinkable film substrate and to form the printed film into a tubularsleeve that can be fitted over and applied to a glass or plasticcontainer, such as a bottle. When such a label is to be applied to acontainer having a narrowed neck portion (such as a wine bottle), theapplication of the coatings on the inner and/or outer sides of the filmmay be gradated in density in proportion to the expected amount ofshrinkage in a given area of the label in order to provide a uniformdensity of the ink coatings and a uniform appearance after shrinkage. Inother words, in the areas where the over-wrap sleeve will be subject toa greater degree of shrinkage, the ink coatings should be applied with aproportionately lower density, such that the density of the coatingswill be uniform overall after shrinkage. Alternatively, if it is desiredto have a finished appearance in which the etched or frosted look fadesto a gloss or untreated look on other areas of the finished product,gradation of coating density may be adjusted accordingly.

Another variation of the present invention is to provide areas of thefilm substrate that are kept free of one or both of the coarse coatingsof ink, especially the outer coating, in order to create a cut-outdesign etch effect. Also, the etch effect may be cut-out to correspondwith indicia, which is preferably printed on the inner side of atransparent film substrate, so that the indicia will show through with agloss or non-etched/frosted effect and be protected from scuffing. Inether case, the appearance imitates that of a genuine etched glasscontainer so presented.

Many variations of the examples as described above may be made withoutdeparting from the spirt of the present invention. As such, the scope ofpatent protection should be limited only by the following claim orclaims, interpreted according to accepted doctrines of claiminterpretation, including the doctrine of equivalence and reversal ofparts.

What we claim is:
 1. A process for producing a film covering forproviding a simulated etched or frosted appearance when applied to asurface, comprising: providing a film substrate having an inner side andan outer side, the inner side to be applied toward the surface beingtreated; applying a coating of translucent ink to the inner side of thefilm; and applying a coating of matte ink to the outer side of the film.2. A process according to claim 1, further comprising the addition ofabout 2% to about 5% by weight silicon powder to at least one of thecoatings of ink.
 3. A process according to claim 2, wherein the inkcoatings are applied to the film using a gravure cylinder.
 4. A processaccording to claim 3, wherein the gravure cylinder is engraved to a celldepth of about 20 to about 40 microns and a line screen of about 125 toabout 200 lines per inch.
 5. A process according to claim 1, furthercomprising applying a coating of translucent color-pigmented ink on theouter side of the film prior to the coating of matte ink.
 6. A processaccording to claim 5, wherein the color is selected to imitate theappearance of the intended contents of a container to which a label madefrom the film covering is subsequently to be applied.
 7. A processaccording to claim 5, further comprising the addition of about 2 to 5%by weight silicon powder to at least one of the coatings of ink.
 8. Aprocess according to claim 7, wherein the ink coatings are applied tothe film using a gravure cylinder.
 9. A process according to claim 8,wherein the gravure cylinder is engraved to a cell depth of about 20 toabout 40 microns and a line screen of about 125 to about 200 lines perinch.
 10. A process according to claim 1, wherein the ink coatings areapplied to the film using a gravure cylinder.
 11. A process according toclaim 10, wherein the gravure cylinder is engraved to a cell depth ofabout 20 to about 40 microns and a line screen of about 125 to about 200lines per inch.
 12. A process according to claim 1, wherein the filmcomprises a heat-shrinkable material and is formed into a sleeve forapplication to the surface of an object by subsequent application ofheat to cause the film to closely form to the object which is to be madeto have the appearance of being etched or frosted.
 13. A processaccording to claim 12, wherein at least one of the coatings is appliedwith a gradient of density on at least part of the film such that theresulting density of the coating appears to be substantially uniformafter a predetermined non-uniform shrinkage of the film.
 14. A processaccording to claim 1, wherein at least one selected area of the film isexcluded from at least the outer side coating in order to provide theappearance of a cut-out pattern of etched or frosted appearance.
 15. Aprocess according to claim 1, wherein at least one selected area of thefilm is excluded from at least the outer side coating and indicia isprinted on the inner side of the film corresponding to the selected areasuch that the indicia will appear through the film without an etched orfrosted effect.
 16. A process for providing a simulated etched orfrosted appearance for a surface, comprising: providing a substantiallytransparent film substrate having an inner side and an outer side, theinner side to be applied toward the surface being treated; applying acoating of translucent ink to the inner side of the film; applying acoating of matte ink to the outer side of the film; applying the film toa surface to provide a simulated etched or frosted appearance.
 17. Aprocess according to claim 16, further comprising applying a coating oftranslucent color-pigmented ink on the outer side of the film prior tothe coating of matte ink.
 18. A process according to claim 17, whereinthe color is selected to imitate the appearance of the intended contentsof a container to which a label made from the film covering issubsequently to be applied.
 19. A process according to claim 16, whereinat least one of the coatings of ink includes about 2% to about 5% byweight silicon powder.
 20. A process according to claim 19, wherein theink applied to the inner side includes about 3% by weight silicon powderand the ink applied to the outer side includes about 5% by weightsilicon powder.
 21. A process according to claim 19, wherein the coatingof ink are applied to the film with a gravure cylinder engraved to acell depth of about 20 to about 40 microns and a line screen of about125 to about 200 lines per inch.
 22. A process according to claim 16,wherein the film comprises a heat-shrinkable material and is formed intoa sleeve for application to the surface of an object by subsequentapplication of heat to cause the film to closely form to the objectwhich is to be made to have the appearance of being etched or frosted.23. A process according to claim 22, wherein at least one of thecoatings is applied with a gradient of density on at least part of thefilm such that the resulting density of the coating appears to besubstantially uniform after a predetermined non-uniform shrinkage of thefilm.
 24. A process according to claim 16, wherein at least one selectedarea of the film is excluded from at least the outer side coating inorder to provide the appearance of a cut-out pattern of etched orfrosted appearance.
 25. A process according to claim 16, at least oneselected area of the film is excluded from at least the outer sidecoating and indicia is printed on the inner side of the filmcorresponding to the selected area such that the indicia will appearthrough the film without an etched or frosted effect.